I'm making a custom case for my mini-itx board, and I've been trying to decide what style of vent to use on the top for a large fan. The two options I've been toying with are either an open cutout with a typical fan grill/guard, OR make the typical hex grille cutouts.

Any thoughts? Do I have to worry about EMI escaping through a large fan opening using a fan grill/guard? (120 - 140 mm fan)

Most ITX builds doesn't need a very fast rotating fan either, which lessens the turbulence/resistance effects of grates. But in general I'd go with nothing more than the fans own plastic guard or a cut down(like every other ring or so) wire grill. EMI is not a problem unless you have something sensitive in the general direction of the hole, and also depends on what kind of parts are nearest the opening. Any chance of designing the opening elsewhere than on the top? I'd generally prefer to have a side or rear vent in order to lower the risk of whatever things coming into the system from above, if there's a real chance for choice. Convection inside a case is such a weak force anyway if there's to be an exhaust fan rotating at any speed.

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